Chewing gum manufacture

ABSTRACT

A chewing gum sheet is formed without substantial use of a powdered non-stick agent by extruding a slab having a tacky surface of heated chewing gum composition onto a moving conveyor; cooling the slab on the conveyor sufficiently to cool the surface of the slab; and passing the slab from the conveyor through at least one cooled roller to form a chewing gum sheet with predetermined dimensions.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 35 U.S.C. §371 national stage application ofPCT/US2009/002406, filed Apr. 17, 2009, and additionally claims benefitto U.S. Provisional Application No. 61/046,249, filed Apr. 18, 2008,incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates to manufacture of a confectionery material havinga tacky surface such as chewing gum and more particularly relates to aprocess and apparatus for manufacture of chewing gum without substantialuse of a rolling compound or powdered non-stick agent.

Chewing gum, commercially distributed as pieces such as sticks, tabs orpillows and which may be coated or filled, typically is produced bycombining chewing gum components including a gum base, flavors,sweeteners, fillers, and binders; extruding such combined componentsinto a slab of typically tacky gum composition material; rolling suchslab into a uniform flat sheet of a desired thickness and width; scoringthe uniform flat sheet into individual pieces; and ultimately packagingthe resulting pieces. During processing, the extruded slab of chewinggum material must pass through a series of calender and scoring rollersto produce the ultimate product. In a conventional process, a rollingcompound or powdered non-stick agent must be applied to the sheet duringprocessing to avoid sticking or fouling of the rollers by a tacky gummaterial.

Use of extensive amounts of a rolling compound or powdered non-stickagent may cause manufacturing difficulties in controlling powderedmaterial in the atmosphere, adds to manufacturing cost, createsdifficulties in handling, increases processing time, may increasevolatization of flavors and may create a porous non-uniform outersurface. A process which could substantially reduce or eliminate theneed to use a rolling compound or powdered non-stick agent in a gummanufacturing process would be an improvement in the art.

SUMMARY OF THE INVENTION

A chewing gum sheet is formed without substantial use of a powderednon-stick agent by extruding a slab having a tacky surface of heatedchewing gum composition onto a moving conveyor; cooling the slab on theconveyor sufficiently to cool the surface of the slab; and passing theslab from the conveyor through at least one cooled roller to form achewing gum sheet with predetermined dimensions.

According to one aspect of the present invention, a process formanufacturing a chewing gum sheet without substantial use of a powderednon-stick agent is provided. The method includes extruding a slab havinga tacky surface of heated chewing gum composition and passing the slabthrough at least one cooled roller to form a chewing gum sheet withpredetermined dimensions.

In accordance with another aspect of the invention, an apparatus forproducing a chewing gum sheet is provided. The apparatus includes anextruder for extruding the chewing gum mass into a slab having a tackysurface of heated chewing gum, a conveyor for receiving the chewing gumslab, an impingement air flow system for cooling the chewing gum slabupon the conveyor and at least one cooled roller for receiving thechewing gum slab from the conveyor and forming the chewing gum sheetwith predetermined dimensions.

In accordance with still another aspect of the present invention, asystem for producing chewing gum pieces is provided. The system includesa mixer for producing a chewing gum mass, an extruder for extruding thechewing gum mass into a slab having a tacky surface, a cooled formingand scoring unit for manipulating the slab into a chewing gum sheet withlateral and/or longitudinal scores and a cooled conveying system forreceiving the chewing gum sheet and cooling the surface of the chewinggum.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic view of a manufacturing process according to thisinvention utilizing a chewing gum piece coater.

FIG. 2 is a view of a chilled calender roller as used in this invention.

FIG. 3 is a view of an alternate chilled roller as used in thisinvention.

FIG. 4 is a schematic view of a forming process according to thisinvention.

FIG. 5 is a schematic view of a manufacturing process according to thisinvention illustrating trays for collecting sheets of chewing gum.

FIG. 6 is a schematic view of a manufacturing process according to thisinvention illustrating a single tier post-cooling unit.

FIG. 7 is a schematic view of a manufacturing process according to thisinvention illustrating trays for collecting sheets of chewing gum fortransport directly to a tempering room.

FIG. 8 is a schematic view of a manufacturing process according to thisinvention utilizing a forming unit without pre-scoring cooling orpost-scoring cooling.

DESCRIPTION OF THE INVENTION

In a process, apparatus, and system of this invention, a slab or sheetof a confectionery material having a tacky surface, such as a chewinggum material, is processed through forming, rolling, and scoring withoutsubstantial use of a rolling compound or powdered non-stick agent.Typically, a confectionery material having a tacky surface underprocessing conditions is manufactured as a rolled sheet having a set orpredetermined thickness and width. From such rolled sheet, portions maybe separated and packaged for commercial sale.

The confectionery material may be any hard candy, soft candy, chewinggum, or other confectionery substance, or compound that has a fluidphase or may take a flowable form. In other words, the confectionerymaterial may be any material that may be heated, melted, or dissolved toform a syrup, or be dissolved in a liquid to become flowable as iscommonly known in the art. Nonlimiting examples of suitableconfectionery materials that are flowable or may be placed into aflowable state include syrups, liquids or solids for making hardcandies, soft candies, lollipops, fondants, toffees, jellies, chewinggums, chocolates, gelatins and nougats. The confectionery material mayinclude sugar or may be sugar-free. Coloring may be added to theconfectionery substrate as desired. The confectionery material may alsoinclude a pharmaceutical product or a medicament.

The preferred confectionery produced according to this invention is achewing gum. Typically, a chewing gum material suitable for use in theprocess of this invention is composed of a gum base, flavorings, andsweeteners and may contain other components such as fillers and binders.Because of the viscoelastic characteristics of chewing gum materials,these materials are formed at elevated (above room or ambient)temperatures into sheets and pieces suitable for commercial sale.Further, chewing gums having desirable characteristics such as, but notlimited to, flavor release, elasticity, soft texture, typically have atacky surface at processing temperature conditions. In order to processsuch tacky materials through processing equipment such as rollers, apowdered non-stick agent (sometimes referred to as a rolling compound)is applied to prevent the rolled gum mass from sticking to processingequipment. This is similar to using flour as a non-stick agent inrolling pie or cookie dough.

In an embodiment, chewing gum is manufactured in a process substantiallywithout a non-stick agent. In such process, the chewing gum is produced,extruded and scored laterally and longitudinally substantially withoutapplication of a non-stick agent. As referred to herein, “non-stickagent” includes sugar, sugar alcohols, calcium carbonate, oil and otherparticulates or lubricants specifically applied to the surface ofchewing gum to prevent sticking of the chewing gum to processingmachinery such as conveyors, glide plates, and rollers. Typically, thenon-stick agent is in powder form. As further referred to herein,“without substantial use of a non-stick agent” means less than or equalto 0.18 weight % non-stick agent based upon the slab weight which exitsan extruder.

In an embodiment of this invention, a chewing gum surface is cooled toreduce tackiness. The surface may be cooled using chilled rollers, air,or other cooling apparatus. In an embodiment of this invention, thesurface temperature of gum material exiting a slab extruder is loweredprior to passing through chilled rollers by using air or other gasdirected to strike the surface of such material to transfer heat awayfrom the gum material. This type of air typically is referred to as“impingement air” and preferably streams of such impingement air aredirected at both surfaces of a moving slab or sheet of gum materialduring processing.

The term “tacky” or “tacky surface” refers to a property of aconfectionery such as a chewing gum material in which the surface ofsuch material is adhesive or gummy to the touch such that portions ofsuch material will tend to adhere to each other or to processingequipment parts such as rollers, and “substantial adhesion” means acondition in which such material joins to processing equipment parts toan extent that requires stoppage or interruption in processing, which isreferred to as “downtime.”

The term “rollers” includes scoring rollers, calender rollers, embossingrollers, and other rollers which typically are rolling cylinders whichcontact a gum material and function to form, shape, flatten, score, cut,conduct heat, emboss, otherwise process, or provide movement to a slabor sheet of such material. “Scoring rollers” includes circular scoringrollers which score (e.g., place an indentation into gum material) orcut the chewing gum longitudinally, cross scoring rollers which score orcut the chewing gum laterally or forming rollers which score or cut achewing gum laterally and longitudinally. “Calender rollers” (sometimesreferred to as “calender rolls”) includes rollers which contact thesurface of the chewing gum typically without scoring or cutting andinclude rollers which may reduce the thickness of the chewing gum,reduce surface imperfections upon the chewing gum, provide embossing,and contact the surface of the chewing gum to impart heat transfer.“Forming rollers” may include calender rollers, scoring rollers,embossing rollers, and the like, which shape or process a gum sheet. Theterm “rollers” also includes systems comprising two rollers, a rollerand a conveyor, a roller and a glide plate, and other systems whichaffect the chewing gum surface through scoring, cutting, surfacethickness or imparting heat transfer using at least one rotatingcylinder. Rollers may have a non-stick surface coating such aspolytetrafluoroethylene (such as sold under the Teflon® brand) orpolished stainless steel.

The terms “chilled rollers” or “cooled rollers” refer to rollers whichhave had their surface temperature lowered below ambient temperature. Inan embodiment, the surface temperature is lowered by circulating coolantliquid through or within the roller. Typical coolant materials includepropylene glycol, ethylene glycol, and aqueous solutions thereof andsalt-containing solutions such as saline solutions. The temperature ofthe chilled rollers typically is below the temperature of the surface ofthe chewing gum during processing and may be well below the freezingpoint of water. The rollers are cooled sufficiently to maintain thesurface of a chewing gum slab or sheet in a cooled state during the timeof contact between the roller and the slab or sheet as to not requiresubstantial (and preferably no) powdered non-stick agent. Typically, thesurface of the chilled roller is maintained at a temperature below 0° C.(32° F.), preferably below −5° C. (23° F.) and more preferably below −7°C. (19° F.). The chilled roller should be at a temperature low enough tohave non-stick properties but not so cold as to make the sheet brittleor otherwise unworkable. The surface of the chilled roller is typicallyabove −15° C. (5° F.), preferably above −10° C. (14° F.) and morepreferably above −9° C. (16° F.).

Typically, the dew point of the air surrounding the chilled rollers usedin this invention is controlled to prevent water condensation on thechilled rollers.

The slab of chewing gum composition, which exits an extruder, is cooled,typically with impingement air, such that preferably both surfaces ofthe slab are cooled with respect to the interior of the slab. A warmcenter will tend to reheat the surface without further surface coolingand will produce a slab which is sufficiently flexible and formable topermit further processing. A totally cooled slab would be less flexibleand more difficult to process through calender or scoring rollers.

The slab of extruded chewing gum composition (which is heated to atemperature consistent with extrusion) is transferred from an extruderonto a moving conveyor, which functions to transport the slab to formingrollers. Although typically the slab passes directly from the extruderexit onto the moving conveyor, chilled forming rollers may be insertedbetween the extruder and the conveyor. Typically, the conveyor is anopen web or mesh such that contact between a heated slab and thetypically metallic (such as stainless steel) conveyor is minimized andthe ability for air flow on both surfaces of the slab is maximized. Atypical conveyor is a continuous roll of an open mesh which moves overtransport rollers. The length of the conveyor is designed to besufficient for the surface of the transported slab to be sufficientlycooled to subsequently pass through a first cooled calender roller.

In accordance with this invention, the surfaces of the slab of chewinggum composition are cooled as the slab is conveyed from the extruder toa series of cooled forming rollers. Typically, the surfaces are cooledby contact with impingement air directed from air jets positions aboveand below the conveyor. Although the preferable system is for theconveyor to be constructed as a mesh or open web in order to facilitateimpingement air directed at both surfaces, other systems are possiblesuch as using a cooled conveyor belt or other systems which permitinitial surface cooling of the chewing gum slab.

Surface cooling may be controlled such as by the length of the conveyorsystem, the temperature of the cooling impingement air, the velocity ofthe cooling impingement air, and the linear speed of the conveyorsystem. The extent of cooling should be sufficient to permit the slab topass through subsequent cooled forming rollers without undue sticking orfouling without use of a powdered non-stick agent. Preferably, thetransported slab is not cooled to a low temperature (especially a lowtemperature throughout the slab), which makes the slab difficult toprocess in the forming rollers.

Impingement air is not used with powdered non-stick agents because thenon-stick agents would be blown from surface of the slab, which wouldcause manufacturing problems. Typically, the temperature of the slabprior to cooling is between 53° C. (127° F.) and 37° C. (100° F.). Ithas been discovered that cooling impingement air creates a surfacetemperature that is cooler than the center of the slab. Typically,surface temperature may be reduced to less than 50° C. (122° F.),preferably less than 37° C. (95° F.), and more preferably less than 33°C. (92° F.). Typically, the surface of the chewing gum composition slabis cooled about 2° C. (4° F.) to 10° C. (19° F.) relative to the centerof the slab. The surface is not reduced to a temperature so cold as tocool the core to a point at which the temperature of the core becomesunworkable. Typically, surface temperature should be above 26° C. (80°F.), preferably above 30° C. (85° F.), and more preferably above 32° C.(90° F.).

The chewing gum will not adhere to the processing equipment if theprocessing equipment includes non-stick equipment, the chewing gum isconditioned to prevent adhering to the processing equipment (i.e.through surface treatments or other conditioning, or if a non-stickagent is applied to the surface of the tacky chewing gum. Such non-stickagents include sugar, sugar alcohols, calcium carbonate, oil, or otherparticulates. Non-stick agents used in excess are generally undesirableas they produce environmental dust, create potential product changeoverissues, and are an additional expense as the non-stick agent may belater removed prior to coating the chewing gum or packaging the chewinggum in wrappers. In an embodiment of this invention, a small,non-substantial, amount of rolling compound may be used to reduce thetackiness but not completely eliminate tackiness. Typically, suchaddition of non-stick agent is in an amount less than or equal to 0.18weight % non-stick agent based upon the slab weight which exits theextruder, preferably less than 0.15 wt % and more preferably less than0.10 wt %.

In an aspect of this invention, the post-extrusion cooling conveyorcools the surface of the chewing gum to reduce tack yet leaves thechewing gum pliable to permit easy forming and scoring. In a relativelyshort period of time, heat from the core of the chewing gum will conducttoward the surface; however, at a typical velocity of the conveyor, thetemperature differential is maintained through the forming rollers.

After the surface of the chewing gum composition slab has cooledsufficiently to permit contact with a cooled solid surface withoutsticking or fouling, the cooled slab is transferred from a movingconveyor to a cooled roller, typically a cooled calender roller andpreferably a double roller in which the slab travels between two movingrollers. Preferably the moving slab does not contact the static base ofthe roller apparatus and is transferred directly from a moving conveyorto the roller. Preferably, the base of the roller is set below the toplevel of the conveyor. Typically, the initial calender roller forms thechewing gum slab into a uniform sheet with predetermined width andthickness dimensions depending upon the size of the roller mechanism andthe space between the rollers. One or more cooled calender rollers maybe used.

Typically, after a uniform sheet of chewing gum is formed, the sheetpasses through one or more (typically two) scoring rollers, which dividethe chewing gum sheet into individual pieces such as sticks, tabs,pillows, or other segments for further processing. Typically, only anindentation is made on the sheet for the pieces, which are separated andprocessed in a subsequent step. Preferably, the scoring rollers also arechilled or cooled.

Further aspects of the processes, systems, and apparatuses of thisinvention are described with reference to the figures. FIGS. 1 and 5-8illustrate embodiments of Apparatus 10. FIGS. 2 and 3 illustrateembodiments of the chilled rollers and FIG. 4 illustrates an embodimentof the chilled rollers in a closure.

Apparatus 10 includes a mixer or mixing unit 12, which may be acontinuous mixer. If mixing unit 12 is a continuous mixer, thecontinuous mixer may be capable of mixing both chewing gum base andfinished chewing gum composition. Mixing unit 12 may also be a batchmixer in which finished gum is made from pre-made chewing gum base.Irrespective of whether the mixing unit 12 continuously produces chewinggum or batch mixes chewing gum, the mixing unit is sized at least toaccommodate the maximum throughput of manufacturing apparatus 10. Atypical throughput of apparatus 10 is between 500 and 5500 kg/hour (1100and 12,000 lbs/hour) and more preferably between 2750 and 4500 kg/hr(6000 and 10,000 lbs/hour)

The mixing unit 12 discharges chewing gum to a conveyor 14. The chewinggum may be in the form of a chewing gum loaf, a continuous extrudate, asemi-continuous extrudate or other forms or strands of chewing gumcomposition. Chewing gum mixed in the mixing unit has a typical outputtemperature between 50-53° C. (122-127° F.). In order to accommodatepotential differences in the temperature and/or rheological propertiesof chewing gum exiting mixing unit 12, the chewing gum may reside uponthe conveyor 14 for a period of time typically from 1 minute to 20minutes. In an embodiment, the conveyor 14 may be exposed to ambient air(typically about 15-25° C. (59-77° F.)). Alternatively, the conveyor 14may be exposed to conditioned air. The conditioned air is typicallybetween 1.5-10° C. (35-50° F.), preferably between 3.3-8.3° C. (38-47°F.) and more preferably between 6-7° C. (43-45° F.), The conditioned airmay also have a relative humidity between 36 and 40 percent. The term“rheology properties” includes deformation, flow, and elasticproperties. Rheological properties of chewing gum are influenced bytemperature, crystallization of sugar or polyols, formulation of chewinggum, and other factors. Chewing gum exiting the conveyor 14 will have atemperature between 48-53° C. (118-127° F.) with a typical temperatureof between 50-53° C. (122-127° F.).

Chewing gum composition enters a forming extruder 20 via a receivinghopper 22. An extruder screw 24 or extruder screws receive chewing gumfrom the hopper 22. The extruder 20 extrudes the chewing gum through die26 into a slab. The extruder 20 may be an extruder as manufactured byTogum (Model 240) or Bosch (Model 1030 and 1050). The extruder 20 mayinclude a water jacket with water circulating at between typically48-50° C. (118-122° F.). Additionally, the extruder adds heat to thechewing gum by friction. The temperature of the composition in theextruder is such to permit movement through the extruder but not at sucha high temperature as to volatize flavors or deform upon exit from thenozzle. Typically the temperature of the composition exiting theextruder is less than 53° C. (127° F.), preferably less than 50° C.(122° F.) and still preferably less than 49° C. (120° F.). Also, thetemperature of the composition exiting the extruder is typically above37° C. (98° F.), preferably above 43° C. (110° F.) and more preferablyabove 47° C. (116° F.). The extruder 20 may extrude the chewing gum fromthe die 26 at a consistent pressure and temperature. Alternatively, theextruder 20 may adjust the pressure and temperature based upon feedbackfrom downstream processes such as conveyors, forming equipment, etc.

A slab of chewing gum may be in a regular slab format. Typically,thickness of a regular slab is 3 to 12 cm (1 to 5 in) and morepreferably between 5 and 10 cm (2 and 4 in). A regular slab may have awidth between preferably 10 and 40 cm (4 and 16 in) and more typically20 to 30 cm (8 and 12 in).

Alternatively, chewing gum may be extruded from die 26 in a thin slab orribbon. The thin slab may have a thickness typically from 0.15 to 3 cm(0.06 to 1.2 in), and more typically, from approximately 0.4 cm (0.16in) to approximately 0.5 cm (0.20 in), 0.76 cm (0.30 in) or 1.02 cm(0.40 in). This slab may have a typical width from approximately 10 cm(4 in) to approximately 70 cm (28 in) wide and more typically from 2.5to 55 cm (1 to 22 in) wide. The thickness of the slab may depend uponwhether the chewing gum is to be formed into a chewing gum stick, tab,or pellet.

In an embodiment, the extruder 20 may be capable of extruding a slab ofchewing gum at a rate between 550 and 5500 kg/hr (1200-12,000 lbs/hr).More specifically, the extruder 20 may be capable of extruding a thinslab between 2000 and 5000 kg/hr (4,400 and 11,000 lbs/hr). In anadditional embodiment, the extruder is capable of extruding between 2750and 4500 kg/hr (6,000 and 9,900 lbs/hr).

The chewing gum exiting the extruder 20 may have a tacky surface due toformulation, temperature, rheology or other factors. Under suchprocessing conditions used in this invention, the chewing gum may beformed, scored or cut without adhering to the processing equipment andcreating down time.

The chewing gum exiting the die 26 is transferred to a conveyor 34.Conveyor 34 is preferably wire mesh which has a minimum of contact areawith the chewing gum. Preferably the conveyor is a stainless steel openmesh style conveyor. Such preferred conveyor 34 typically has an area ofcontact with the chewing gum of between 10-75 percent of the totalconveyor area, preferably between 25-50 percent of the total conveyorarea and more preferably between 30-40 percent of the total conveyorarea.

The chewing gum exiting the die 26 may be passed through one or morecalender rolls (not shown) to size the chewing gum or smooth any surfaceirregularities. Such calender rolls are preferably chilled. Chilledrollers controlling the surface temperature permit tacky slabs orribbons of chewing gum to pass between the chilled rollers withoutadhering to such an extent as to cause down time. As seen in FIGS. 1, 5,6 and 7, the conveyor 34 may be adjacent at least one convective coolingunit 36. Convective cooling unit 36 may be supplied by air from supplysystem 40. Supply system 40 may provide conditioned air which istemperature and relative humidity controlled. The air supply system 40may be adjusted to condition the chewing gum slab or the surface of thechewing gum slab. The conditioned slab is less likely to stick toconveyor 34, calender rolls 32 or forming unit 50. Alternatively, asillustrated in FIG. 8, the apparatus 10 may not include a convectivecooling unit.

The air supply ducts are connected to impingement air nozzles 38 whichdirect air onto the conveyor from a range of 240 meters per minute “MPM”(800 feet per minute (“FPM”)) to 1200 MPM (4000 FPM) and more preferablyto approximately 900 MPM (3000 FPM). Impingement air nozzles 38 may befacing a top surface of the chewing gum slab, a bottom surface of thechewing gum slab projecting air through conveyor 34, or a combination ofboth top and bottom surfaces.

The area between the extruder die 26 and the forming unit 50 may begenerally referred to as a post-extruding cooling unit 30. Thepost-extruding cooling unit 30 cools and/or conditions the chewing gumslab for consistent scoring of the chewing gum pieces. Thepost-extruding cooling unit 30 may alter the properties of the surfaceof the chewing gum or may completely cool the chewing gum. In apreferable embodiment, the post-extruding cooling unit 30 cools thesurface of the chewing gum to reduce tack yet leaves the chewing gumpliable to permit easy scoring. Given a relatively short period of time,heat from the core of the chewing gum will conduct toward the surface;however, given the velocity of the conveyor, a temperature differentialmay be maintained through the forming unit 50.

In an embodiment, forming unit 50 may be made up of sizing rolls orcalender rolls 32, cross scoring unit 52 and a circular scoring unit 54.

FIG. 2 illustrates a suitable calender roll 32 configuration for use inthis invention. Preferably, the base of the chewing gum 44 is maintainedon the same plane when passed from mesh conveyor 34, across glide plate42, through the calender roll despite the calender roll reducing thewidth, and onto transfer conveyor 56. As such, the cooling load of thetop calender roll is increased but the plane of processing is maintainedconstant. This configuration of calender rolls 32 may also be used forcross scoring unit or rolls 52 and circular scoring unit or rolls 54.

FIG. 3 illustrates another suitable calender roll configuration for usein this invention. Alternatively, the chewing gum 44 is approximatelycentered between two calender rolls 32. As such, the cooling load ofboth the top and bottom calender roll is evenly distributed but theplane of processing is changed from one side of the calender rolls 32 tothe next. However, the base of the chewing gum is maintained on a firstplane when passed from mesh conveyor 34 and across a first glide plate42 but on a second plane exiting the calender rolls 32, across a secondglide plate 42 and onto a transfer conveyor 56. This configuration ofcalender rolls 32 may also be used for cross scoring unit 52 andcircular scoring unit 54.

The configurations as seen in FIGS. 2 and 3 permit adjusting the widthof the chewing gum 44 by adjusting the top calender rolls. It has beenfound that adjusting the top calender roll is easier to control than thebottom calender roll. Although not illustrated in FIGS. 2 and 3, therollers of the forming unit 50 may have a similar configuration. Thecalender rolls may be configured to permit the chewing gum 44 to movedirectly to a glide plate, a moving conveyor or additional rollers.Preferably, the rolls are configured to avoid contact with stationaryparts.

The transfer conveyor 56 is preferably a solid conveyor using a foodgrade polymer belt. The transfer conveyor 56 permits controlled transferof the chewing gum from the calender rolls 32 and an internal scoringunit (either cross scoring unit 52 or circular scoring unit 54 whicheveris placed internally). The transfer conveyor belt should be fabricatedfor minimal deformation during stopping and starting of the belt toprevent deformation in the chewing gum during stopping, starting, andspeed fluctuations.

The cross scoring unit 52 and the circular scoring unit 54 may be pairsof scoring rollers. Alternatively, the scoring units 52, 54 may be asingle roller scoring the chewing gum against a conveyor. Stillalternatively, the forming unit 50 may use a set of forming rollers or aforming roller against a conveyor which simultaneously cross andcircular scores. The forming unit 50 may make a slight indentation inthe chewing gum slab which would require additional processing steps toseparate the chewing gum pieces. Alternatively, the forming unit 50completely separates the chewing gum into individual pieces.

The forming unit 50 may include glide plates 42 between an adjacentcalender roll 32, cross scoring unit 52, or circular scoring unit 54.When using glide plates, the rollers themselves provide velocity to thechewing gum to move the chewing gum to the next set of rollers or toanother conveyor. Glide plates may be coated with a non-stick materialsuch as polytetrafluoroethylene or polished stainless steel.Conventionally, however, coating rollers or glide plates with anon-stick material such as polytetrafluoroethylene is not preferred dueto manufacturing cost and a tendency of pieces of a coating to come offduring processing.

As seen in FIG. 4, conveyors 56 may be between and adjacent calenderroll 32, cross scoring unit 52, or circular scoring unit 54. When usingconveyors 56, chewing gum may move directly from the rollers to theconveyor without use of a glide plate 42. Alternatively, a glide platemay be included for incidental contact and support during downtime butnot during production. As such, the chewing gum does not encounter astationary contact surface during production.

To further permit product flow, glide plates 42 may include indentationsor grooves matched to the chewing gum passing through the scoringsystem. During circular scoring, the chewing gum may take on a roundedshape and indentations or grooves may be placed upon the glide plate toaccommodate the rounded shape.

Scoring rollers preferably are chilled. Alternatively, the scoringrollers are coated with a non-stick material such aspolytetrafluoroethylene. Still alternatively, the scoring rollers arechilled and coated with a non-stick material such aspolytetrafluoroethylene. Scoring rollers have not previously been coatedwith a non-stick material due to the protrusions upon the scoringrollers and the likelihood of having the non-stick material come off ofthe scoring rollers.

The scoring rollers may also be in a temperature and humidity controlledenvironment such as being enclosed in an insulated and sealed closure58. The environmental air around the scoring rollers may have a dewpoint just above the temperatures of the rollers. Under such conditionsa thin layer of moisture may accumulate on the rollers and enhance thenon-stick properties of the scoring rollers.

Alternatively, a closure 58 may be provided to control the environmentabout the scoring system 50 which may be conditioned to have a dew pointof −13 to -12° C. (8 to 10° F.). Under such conditions, the temperatureof the rollers may be cold and the surface of the rollers dry. Surfacetemperatures from −12 to −6° C. (10 to 20° F.) permit the chewing gum topass through the scoring system 50 without adhering to the rollers.

Still alternatively, the environmental air around the rollers may have adew point above the temperature of the rollers and the rollers have atemperature below freezing temperature. Under such conditions ice mayform upon the rollers and create non-stick surface properties.

Upon exiting the forming unit 50, in one embodiment, the chewing gumslab may enter a post-scoring area where the chewing gum is treated forlater packaging and/or processing. In the embodiment illustrated in FIG.7, the post-scoring area is a tempering room 86. In this embodiment,products exiting the forming unit 50 are transported using a conveyor 68to trays 80. The chewing gum may be stacked as sheets into trays 80which may be on a rotating conveyor 82. A non-stick agent may be appliedin between each sheet to prevent the sheets from sticking to one anotherduring storage or while waiting to be fed into a wrapping machine. Thetrays 80 may be moved via a conveyor 84 to tempering room 86.

The tempering room holds the chewing gum slab for a pre-determinedperiod such that the chewing gum hardens for packaging, such as forstick and/or tab chewing gum, or further processed in a pellet coatingmachine. Alternatively, the post-scoring area may include a post-scoringcooling unit 60.

As seen in FIGS. 1, 5 and 6, the post-scoring cooling unit 60 mayinclude a cooling area which supplies cooled air through air ducts 62.The air ducts 62 may be supplied by air supply 40 which is alsosupplying the air ducts 36 in the pre-scoring area 30. The post-scoringair supply ducts may supply one-way impingement ducts 64 or two-wayimpingement ducts 66.

In the embodiment illustrated in FIG. 6, a conveyor 68 receives chewinggum slabs or individual pieces from the forming unit 50. A single passconveyor 68 may have a long length sized to cool the chewing gumentering the post-scoring area at approximately 43° C. to a temperaturebetween 15-20° C. With a single pass conveyor, one-sided impingementducts 64 may be used.

In the embodiments illustrated in FIGS. 1 and 5, the conveyor 68 may bea multi-pass conveyor (i.e. a first conveyor is stacked upon a secondconveyor 68 and third conveyor 68). In this embodiment products from thefirst conveyor 68 drops onto a second conveyor once it has achieved atemperature at which point the chewing gum does not deform during thetransfer or below approximately 35° C. (95° F.). The second conveyorconveys products back under the first conveyor through two-wayimpingement ducts 66. The two-way impingement ducts 66 may also be twoone-sided impingement ducts facing away from one another. Theimpingement ducts 66 blow air both up through the first conveyor 68 anddown upon the chewing gum pieces on the second conveyor. The chewing gumpieces move along the second conveyor to a section of sheet metal orother connector which moves the chewing gum pieces to the third conveyordown below. The third conveyor moves back between an impingement duct 66and an impingement duct 64. The final exit temperature from the thirdconveyor 68 is between 15-20° C. (59-68° C.).

In an alternative embodiment, the post-extruding cooling unit 30 and thepost-scoring cooling unit 60 may be within the same cooling unitenclosure. In such an embodiment, the post-extruding cooling unitincludes a conveyor which passes through the enclosure to a forming unitand then continues through the enclosure for post-scoring cooling. Instill another embodiment, the forming unit may be outside of theenclosure.

As seen in FIG. 1, the chewing gum may be separated into individualpieces and collected in tubs or bulk storage containers for storage andlater use in pellet forming systems such as for making Wrigley Eclipse®chewing gum. The chewing gum may also be sent to a conveyor 70 which mayfeed a piece separator 72. The piece separator 72 breaks the chewing guminto pieces for later feeding into a coating unit 76. A non-stick agentmay be applied during the tumbling to prevent the pieces from stickingto one another during storage or while waiting to be fed into the piececoater or even while sitting in a coater 76 waiting to be coated. Thenon-stick agent is added in amounts less than 1.0% by weight of thetotal chewing gum piece, preferably less than 0.5%, and still preferablyless than 0.2%.

Exiting the tumbler the chewing gum may be sent to storage for temperingor may go immediately to the piece coater 76. When being sent to acoater 76 the pellets may be elevated using a conveyor 74.Alternatively, as seen in FIG. 5, the chewing gum may be stacked assheets into trays 80 which may be on a rotating conveyor 82. A non-stickagent may be applied in between each sheet to prevent the sheets fromsticking to one another during storage or while waiting to be fed into awrapping machine. The trays 80 may be moved via a conveyor 84 to atempering room 86.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present subjectmatter and without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by the appendedclaims.

What is claimed is:
 1. A process for manufacturing a chewing gum sheetwithout substantial use of a powdered non-stick agent comprising: a)extruding a slab having a tacky surface of heated chewing gumcomposition; b) passing the slab through at least one cooled roller toform a chewing gum sheet with predetermined dimensions, wherein the atleast one cooled roller is maintained at a temperature of from 5° F. to32° F.; and further wherein the at least one cooled roller is in atemperature and humidity controlled environment, wherein theenvironmental air around the at least one cooled roller has a dew pointabove the temperature of the at least one cooled roller; c) wherein aclosure is provided around the at least one cooled roller to control theenvironmental air to have a dew point of from 8° F. to 10° F.
 2. Theprocess of claim 1 further comprising the step of conveying the slab ona moving conveyor to cool the surface of the slab.
 3. The process ofclaim 2 in which the chewing gum slab is cooled on a moving conveyorwith impingement air flow.
 4. The process of claim 2 in which thechewing gum slab is cooled on the moving conveyor with ambient air. 5.The process of claim 1 in which the chewing gum slab is conveyed fromthe extruder to the cooled roller without contact with a static deadplate.
 6. The process of claim 1 in which a chewing gum sheet is passedthrough at least one scoring roller with less than or equal to 0.18weight % non-stick agent based on the slab weight.
 7. The process ofclaim 6 in which a chewing gum sheet is passed through laterally and/orlongitudinally scoring rollers.
 8. The process of claim 7 in which thechewing gum sheet is scored into pieces.
 9. An apparatus for producing achewing gum sheet comprising: a) an extruder for extruding a chewing gummass into a slab having a tacky surface of heated chewing gum; b) aconveyor for receiving the chewing gum slab; c) an impingement air flowsystem for cooling the chewing gum slab upon the conveyor; d) at leastone cooled roller for receiving the chewing gum slab from the conveyorand forming a chewing gum sheet with predetermined dimensions, whereinthe at least one cooled roller is maintained at a temperature of from 5°F. to 32° F.; and further wherein the at least one cooled roller is in atemperature and humidity controlled environment, wherein theenvironmental air around the at least one cooled roller has a dew pointabove the temperature of the at least one cooled roller; e) wherein aclosure is provided around the at least one cooled roller to control theenvironmental air to have a dew point of from 8° F. to 10° F.
 10. Theapparatus of claim 9 in which the impingement air flow system is forcooling the top and bottom surfaces of the chewing gum slab.
 11. Theapparatus of claim 9 further comprising at least one scoring roller. 12.The apparatus of claim 11 in which the scoring roller scores the chewinggum sheet laterally and/or longitudinally.
 13. The apparatus of claim 9further comprising a conveyor for receiving the chewing gum sheet, animpingement air flow system for cooling the chewing gum sheet upon theconveyor.
 14. The apparatus of claim 13 wherein the conveyor is amulti-tier conveyor.
 15. The apparatus of claim 9 further comprising anapplicator for applying non-stick agent to the chewing gum sheet. 16.The apparatus of claim 15 further comprising a tray system for stackingthe chewing gum sheets.
 17. The apparatus of claim 9 further comprisinga coating system for separating the chewing gum sheets into individualpieces and coating the individual pieces.
 18. A system for producingchewing gum pieces comprising: a) a mixer for producing a chewing gummass; b) an extruder for extruding the chewing gum mass into a slabhaving a tacky surface; c) a cooled forming and scoring unit formanipulating the slab into a chewing gum sheet with lateral and/orlongitudinal scores, wherein the forming unit comprises at least onecooled roller maintained at a temperature of from 5° F. to 32° F.; andfurther wherein the at least one cooled roller is in a temperature andhumidity controlled environment, wherein the environmental air aroundthe at least one cooled roller has a dew point above the temperature ofthe at least one cooled roller; d) wherein a closure is provided aroundthe at least one cooled roller to control the environmental air to havea dew point of from 8° F. to 10° F.; e) a cooled conveying system forreceiving the chewing gum sheet and cooling the surface of the chewinggum.
 19. The system of claim 18 further comprising a cooled conveyingsystem receiving the chewing gum slab from the extruder and cooling thesurface of the chewing gum.
 20. The system of claim 18 wherein the slabis a ribbon.
 21. The process of claim 1, wherein the extruded slab has athickness of from
 0. 15 cm to 3 cm.
 22. The process of claim 1, whereinprior to passing the slab through the at least one cooled roller, theslab is transferred to a conveyor, and impingement air nozzles directair onto the conveyor from a range of 240 meters per minute to 1,200meters per minute.
 23. The apparatus of claim 9, wherein theenvironmental air around the at least one cooled roller has a dew pointabove the temperature of the at least one cooled roller and the at leastone cooled roller has a temperature of from 5° F. to below 32° F. 24.The apparatus of claim 9, wherein the extruded slab has a thickness offrom 0.15 cm to 3 cm.
 25. The apparatus of claim 13, wherein impingementair nozzles direct air onto the conveyor from a range of 240 meters perminute to 1,200 meters per minute.
 26. The system of claim 18, whereinthe environmental air around the at least one cooled roller has a dewpoint above the temperature of the at least one cooled roller and the atleast one cooled roller has a temperature of from 5° F. to below 32° F.27. The system of claim 18, wherein the extruded slab has a thickness offrom 0.15 cm to 3 cm.
 28. The system of claim 19, wherein the cooledconveying system receiving the chewing gum slab from the extruder hasimpingement air nozzles direct air onto the conveyor from a range of 240meters per minute to 1,200 meters per minute.